Battery charger/tester with storage media

ABSTRACT

A method and apparatus that allows a battery charger/tester to store and retrieve information from a storage media. Information, such as the result of the charge and testing of the battery, can be stored on the storage media. Additionally, information, such as firmware updates, can be uploaded from the storage media.

FIELD OF THE INVENTION

[0001] Embodiments of the present invention generally relate to a powersource charger and tester. More particularly, the present inventionrelates to an apparatus and method that allows data to be stored andretrieved on a battery charger/tester.

BACKGROUND OF THE INVENTION

[0002] Rechargeable batteries are an important source of clean portablepower in a wide variety of electrical applications, includingautomobiles, boats and electric vehicles. Lead-acid batteries are oneform of rechargeable battery that are commonly used to start engines,propel electric vehicles, and to act as a source of back-up power whenan external supply of electricity is interrupted. While not particularlyenergy efficient, due to the weight of lead in comparison to othermetals, the technology of lead-acid batteries is mature. As a result,the batteries are cheap, reliable, and readily produced and thus,continue to constitute a substantial portion of the rechargeablebatteries being produced today.

[0003] The ability of lead-acid batteries to deliver large amounts ofelectrical power is well known, particularly when associated with thestarting and powering of motor vehicles. Because the lead-acid batteriescan be depleted of power overtime, such as when they are not in use overa period of time, or when a light in a car is left on for an extendedperiod of time, they need to be recharged and tested. A number ofbattery testers and chargers have thus been developed to charge and testthe lead-acid battery.

[0004] Most conventional battery charger/tester are equipped to providemultiple charging rates for charging different size batteries. Themultiple charging rates are achieved by varying the charging voltage atthe battery terminals, generally by changing the transformerprimary/secondary winding ratio. An operator manually selects the rateat which the battery should be charged and also the duration of thecharge cycle if the charger is equipped with a timer function.

[0005] Many defects found in lead-acid batteries and other types ofbatteries are the result of poor recharging control in conventionalchargers. For example, an operator may undercharge or overcharge thebattery at a very high rate resulting in the deterioration of thebattery. Overcharging a battery wastes energy, reduces the life of thebattery, and may permanently damage the battery. Additionally,conventional battery chargers can also include testers with theappropriate gauges in order to determine the current state of charge ina battery, how long and at what rate a particular battery should becharged, whether it is safe to charge the battery, and whether thebattery is capable of accepting a charge.

[0006] Once the battery charger/tester is in operation, the operatormust return to check the status of the battery to ensure that thebattery is charging properly. Because conventional battery requiresactual visual inspection of the gauges, the operator can waste valuabletime and money to inspect all the batteries that are currently beingcharged instead of generating money by working on other projects.

[0007] During the charging period of the battery, temperature of thebattery is an indicator as to how successfully the battery is acceptingthe charge. Different batteries accept the charge in a number ofdifferent ways. For example, some batteries heat up beyond a normalrange. Anything beyond this normal range is an indication that thebattery is not accepting the charge in an efficient manner.

[0008] There is a need for a battery charger/tester to include atemperature sensing device, which monitors the device throughout theentire processing charging and testing process. There is a further needto provide the collected temperature data back to the charger to enableit to adjust the charge/test rate of the battery based upon this data.

[0009] After the battery is tested and charged, the results aretypically printed out and kept in file folders for warranty purposes.Because they are stored in file cabinets, it takes time to find thecorrect file (assuming that they were correctly filed) and match it upto the battery. Additionally, paper files often gets misplaced becausethey can be stored in so many different places or often are thrown awaybecause of limited on-site storage. There is a need for an apparatus andmethod to easily match previously tested and charged batteries withtheir previous results. There is a further need for an apparatus andmethod to store information in less space.

SUMMARY OF THE INVENTION

[0010] Embodiments of the present invention generally provide for abattery charger/tester having a storage media. The batterycharger/tester can store information and retrieve information from thestorage media.

[0011] In one embodiment of the invention, a charging apparatus that caninclude a power source charger having a module port, and a removabledata module received in the module port and is in communication with thepower source charger. The power source charger can include a tester. Thepower source charger can also include a controller that is incommunication with the removable data module. The controller can storedata and retrieve data on the removable data module. The removable datamodule can be selected from a group that can include a floppy disc, atape drive cartridge, an optical media, a flash memory, a magnetic basedmedia, a magneto optical, a hard drive, any other removable media and acombination thereof. The removable data module's data can be selectedfrom a group that can include the result of the charging/testing of thebattery, the battery's warranty information, the battery type, thebattery brand, the battery model, previous information regardingcharging/testing of the battery, firmware update, diagnostic oroperating parameters information of the charger, maintenance informationof the charger, any other data required by the operator, and acombination thereof.

[0012] In one embodiment a method of storing and retrieving data for acharging apparatus is provided and can include operating the chargingapparatus, and accessing a removable data module by a microprocessor.The charging apparatus can further include a tester. Operating thecharging apparatus can be charging and testing the battery. Accessingthe removable data module can be storing data resulting from operatingthe battery charger and can be retrieving previously stored data. Theremovable data module can be selected from a group that can include afloppy disc, a tape drive cartridge, an optical media, a flash memory, amagnetic based media, a magneto optical, a hard drive, any otherremovable media, and a combination thereof.

[0013] In another embodiment, a charging system that can include a powersource charger means having a module receiving means, and a removabledata means that can be received in the module receiving means and is incommunication with the power source charger means. The power sourcecharger means can further include a power source testing means.Additionally, the power source charger means can include a controllermeans that is in communication with the removable data means. Thecontroller means can control and store data onto the removable datameans. The controller means can also control and retrieve data from theremovable data means. The removable data means can be selected from thatcan include a floppy disc, a tape drive cartridge, an optical media, aflash memory, a magnetic based media, a magneto optical, a hard drive,any other removable media, and a combination thereof.

[0014] There has thus been outlined, rather broadly, the more importantfeatures of the invention in order that the detailed description thereofthat follows may be better understood, and in order that the presentcontribution to the art may be better appreciated. There are, of course,additional features of the invention that will be described below andwhich will form the subject matter of the claims appended hereto.

[0015] In this respect, before explaining at least one embodiment of theinvention in detail, it is to be understood that the invention is notlimited in its application to the details of construction and to thearrangements of the components set forth in the following description orillustrated in the drawings. The invention is capable of otherembodiments and of being practiced and carried out in various ways.Also, it is to be understood that the phraseology and terminologyemployed herein, as well as the abstract, are for the purpose ofdescription and should not be regarded as limiting.

[0016] As such, those skilled in the art will appreciate that theconception upon which this disclosure is based may readily be utilizedas a basis for the designing of other structures, methods and systemsfor carrying out the several purposes of the present invention. It isimportant, therefore, that the claims be regarded as including suchequivalent constructions insofar as they do not depart from the spiritand scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017]FIG. 1 is a hardware block diagram of an embodiment of the currentinvention.

[0018]FIG. 2 is a hardware block diagram.

[0019]FIG. 3 is a diagram of the process for applying a load to an opencircuit in accordance with a preferred embodiment of the presentinvention.

[0020]FIG. 4 is a flowchart of the process for testing and chargingpartially charged batteries in accordance with a preferred embodiment ofthe present invention.

[0021]FIG. 5 is a flowchart of the process for testing and chargingdischarged batteries in accordance with a preferred embodiment of thepresent invention.

[0022]FIG. 6 is a front view of a display and keyboard of one embodimentof the current invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0023] FIG.1 is an embodiment of the current invention. The batterycharger/tester 100 (“charger 100”) can include a power source 110 thatprovides a 120V (volts) AC (alternating current) to the charger 100. Acircuit breaker 112 is provided to prevent damage that can be caused bya sudden power surge or a short in the system. A power switch 114 islinked to the power source 110 to enable the operator to turn thecharger 100 on or off.

[0024] A power transformer 116 is provided to step down both the voltageand current to a level that enables the charger 100 to charge and/ortest a battery. In a preferred embodiment, the power source 110 suppliesthe charger 100 with 120V AC. The power transformer 116 reduces the 120VAC to approximately 20-25V AC, which is optimal for charging thebattery. Two lines 118, 120 from the power transformer 116 are inputtedinto a rectifier 124 and a third line 122 is directly coupled to thenegative clamp 238. The lines 118, 120 pulse alternately through afull-wave rectifier 124 at a cycle of 60 Hz. The diodes of the rectifier124 convert the positive AC voltage to DC (direct current) power supply.The third line 122 provides a return path for the negative voltage ofoutputs 118, 120 to return to the transformer 116.

[0025] A silicon control rectifier (SCR) 126 or thyristor is included inthe preferred embodiment to regulate the output from the rectifier 124to the battery. Exiting from the rectifier 124 is a pulsed positive sinewaveform with peak voltages and current. The sine waveform results invarying voltages and current being outputted from the rectifier 124. TheSCR 126 essentially operates as a switch allowing certain voltagesand/or current to pass to the battery.

[0026] The operator can choose either a voltage or a current or both tocharge the battery. This selection is called a set-point. This set-pointis then transmitted to a FPGA 142 (field programmable gate array,discussed below), which then determines at which point in the sine waveto allow voltage to pass through to the battery. This point in the sinewave is related to the set-point as chosen by the operator. Theset-point, depending on the selection of the operator, is situated onthe sine wave by starting from the end of the sine wave and working in arearward direction. Once the set-point is located on the sine wave, thevoltage underneath the sine wave is allowed to pass through. Therefore,the set-point voltage is a mean value of a range of voltages.

[0027] For example, if the operator decides to charge the battery at12V, this set-point of 12V is entered into the charger 100. Theset-point is transmitted to the FPGA 142, which then determines at whichpoint in the sine wave to allow the voltage or current to pass throughto the battery. The 12V set-point in this example permits voltageslarger than and less than 12V to pass through to the battery. The meanof the voltages distributed to the battery will approximately equaltwelve volts.

[0028] The SCR 126 operates essentially as a switch and allows currentor voltage to pass to the battery at a set-point fixed by the operator.The SCR 126 can operate based on either voltage, current or acombination thereof. The SCR 126 is normally switched off until itreceives a signal from an I/O control (input/output) 134. The voltage orcurrent exiting from the rectifier 124 is transmitted to an ADC(analog-to-digital converter) 136. The ADC 136 in turn transmits thevoltage or current information to a linked CPLD (computer programmablelogic device) 140, which is linked to the FPGA 142. The FPGA 142,simulating as a processor, determines the operability of the SCR 126 bycomparing the previously programmed set-point value with the outputvalue of the rectifier 124. If the output value of the rectifier 124 isequal or greater than the set-point of the SCR 126, then the FPGA 142instructs the I/O control 134 to send a signal to the SCR 126 to allowthe output voltage or current to pass to the battery. For example, ifthe operator desires a minimum current of 20 amps, the SCR 126 willallow a current equal to or exceeding 20 amps to pass to the battery.

[0029] A current sensor 128 is provided at the output of the SCR 126 tomonitor or sense the current exiting from the rectifier 124 and the SCR126. The current from the rectifier 124 is relayed to the ADC 136, whichlike the voltage is fed to the CPLD 140 and then onto the FPGA 142. TheFPGA 142 verifies if the current from the rectifier 124 is equal to orexceeds the current set-point value. The output from the current sensor128 is connected to the battery clamps 238, 240.

[0030]FIG. 2 illustrates a battery tester charger 200 according to oneembodiment of the invention. A battery 202 having a positive terminal234 and a negative terminal 236 may be attached to the battery testercharger 200 via a positive clamp 240 and a negative clamp 238 located atan end of the respective positive and negative cables 230, 232.

[0031] In a preferred embodiment, the battery tester charger 200 candetermine whether the connections between the battery 202 and the clamps238, 240 are acceptable. A connection test may be performed at eitherthe positive 240 or the negative clamp 238 connection by applying theconnection test to the positive components 230, 240 or negativecomponents 232, 238 of the battery tester charger 200. Of course,applying the connection test to both components will test both thepositive and negative connections. The connection test may be performedby comparing the voltage in the battery cables 230, 232 upstream fromthe connection of the clamps 238, 240, and the voltage at the connectionof the clamps 238, 240. Voltage loss due to cable resistances 208, 210may be considered and subtracted from the difference in voltage at theclamps 238, 240 and the upstream position. Additional differences involtage between the upstream position and the connections of the clamps238, 240 may be caused by clamp connection resistances 206, 204.

[0032] The testing of the battery connections can be applied to eitherthe positive or negative components to test the connections individuallyor can be applied to both components to test both connections. Theexternal battery cables 230, 232 are attached to the respectiveterminals 234, 236 of the battery 202 via the respective clamps 240,238. Standard clamps, such as alligator clamps, may be used.

[0033] A portion 237, 239 (FIG. 1) of each clamp 238, 240 is isolatedfrom the remainder of the clamps 238, 240 and the associated cables 232,230. Portions 237, 239 can be isolated from the remainder of the clamps238, 240 by a non-conductive element. The cables 232, 230 can carry alarge current, either to the battery 202 when charging or from thebattery when the battery is in use. The isolated portions 237, 239 maybe connected to another device to determine the voltage at terminals234, 236. For example, the isolated portions 237, 239 may be attached tohigh impedance wires 226, 224 to differential operational amplifiers214, 212 (opp. amp) as shown in FIG. 2. Alternately, in some optionalembodiments, as shown in FIG. 1, the high impedance wires 226, 224 maybe attached to the ADC 136.

[0034] The battery connections may be tested to determine theresistances 206, 204 associated with the connection when the battery 202is charged by a current source 110 or exposed to a heavy load 144.Whether the battery 202 is charging or in use, large current will flowthrough the cables 230, 232 and clamps 240, 238. A sensor 220, 222 inthe battery charger tester 200 senses the voltage upstream from theclamps 240, 238 and the battery terminals 234, 236 connections andinputs a signal representative of the voltage to opp amps 214, 212 oroptionally to the ADC 136. For example, in some optional embodiments ofthe invention, the voltage may be sensed upstream from the current sense128 in both cables 230, 232 as shown in FIG. 1. As mentioned above,voltage is sensed in the isolated portions 237, 239 and compared to thevoltage sensed upstream. The cable resistances 208, 210 are known, andthe portion of the voltage difference between the voltage in theisolated portions 237, 239 and the voltage at the upstream position isaccounted for by the cable resistances 208, 210. The remaining voltagedifference between the voltage measured at the isolated portions 237,239 and the upstream positions is due to the resistances in the clamps240, 238 and terminal 234, 236 connections. In optional embodiments ofthe invention, cable resistances 208, 210 and the associated differencein voltage due to cable resistances 208, 210, may be neglected orapproximated.

[0035] The resistance of the connections 206, 204 can be analyzed usingOhm's law, V=IR, where V stands for voltage, I stands for current, and Rstands for resistance. Simple algebraic manipulation yields R=V/I. Theunknown connection resistances 206, 204 associated with the connectioncan be expressed in terms of known parameters of current and voltage,thus the resistances 206, 204 can be determined.

[0036] Once the connection resistances 206, 204 are determined, eachconnection can be evaluated to determine whether the connection isacceptable or not. In one embodiment, a method is provided and comparesthe connection resistances 206, 204 against a predetermined acceptableand non-acceptable range of connection resistance. Based on thecomparison, the operator can determine whether the connection isacceptable or not.

[0037] In an alternative embodiment, a method is provided to compare thevoltage differences between the isolated portions 237, 239 and thevoltage in the cables 230, 232 at the upstream positions. If thedifference in voltage between the two locations is negligible, then theconnection is likely to be acceptable. Optionally, the difference involtage due to cable resistances 208, 210 may be subtracted from thevoltage difference or otherwise accounted for in determining whether theconnections are acceptable or not. If the voltage difference is higherthan a predetermined maximum amount, then the connection between thebattery terminal 234 and the clamp 140 will likely be unacceptable.

[0038] If the connection is not acceptable, the battery tester charger200 can alert or notify the operator. In some embodiments, the batterytester charger 200 may alert the operator as to which connection(positive or negative) is unacceptable or whether both are unacceptable.In some embodiments, the battery tester charger 200 may alert theoperator that the connection(s) are acceptable. The operator may bealerted by a variety of ways, such as an indicator light, a message on adisplay screen, an audible signal, or other ways that are disclosedherein. Because the operator is warned that a connection is notacceptable, the operator may take corrective measures to improve theconnection, such as cleaning or replacing the terminals 234, 236 orclamps 240, 238.

[0039] Referring to FIG. 1, in the preferred embodiment of theinvention, a Sabre Battery Test procedure is used as a heavy load testto analyze the condition of the battery. The heavy load test is appliedwith a heavy load 144 that includes a solenoid switch 146. The solenoidswitch 146 is operated by the FPGA 142 through the I/O control 134 viathe CPLD 140. The solenoid switch 146 in the heavy load test ensuresthat a high load amperage test can be efficiently and safely transmittedto the battery. One detraction in incorporating the solenoid switch 146with the heavy load test is that it is not possible to make an exactdetermination of when the heavy load 144 is started or ended. Thisresults from the mechanics of the solenoid switch 146 in that when theswitch is turned off or on, it does not occur immediately. Therefore,there is a delay that fluctuates due to the mechanics of the solenoidswitch 146 which makes exact testing and charging more difficult. One ofordinary skill in the art will recognize that the solenoid 146 can bereplaced with electronic switching devices, such as transistors in analternate embodiment. However, cost considerations drive the design ofthe preferred embodiment and a mechanical solenoid switch 146 wasselected.

[0040] The preferred embodiment analyzes the charge-state of a giventype of battery, determines whether the battery is defective and, ifnot, charges the battery at its most optimum charge rate up to itsmaximum allowed charging volts. Furthermore, the preferred embodimentexecutes its analysis, determination, and charging in the safest andmost optimal time possible.

[0041] In operation, the heavy load test is shown in the Sabre TestTiming Diagram 300 in FIG. 3. The Sabre Battery Test requires a firstapplied load 302 to be placed on an open circuit 304. A battery voltagereading (“LVA15”) 306 can be taken at the end of the first applied load302, which is approximately fifteen seconds after the first load 302 isapplied and released. A bounce back voltage measurement (“Rv”) 308 istaken approximately twenty seconds after the first applied load 302 isturned off. A second applied load 310 is then placed on the open circuit304 and maintained for approximately fifteen seconds. Another batteryvoltage reading (“LVB15”) 312 is taken at the end of the second appliedload 310.

[0042] Heavy load tests are highly accurate for testing chargedbatteries. If the battery to be tested is partially charged, then thetest accurately determines whether the battery is defective. A personskilled in the art will recognize that any heavy load test procedurethat is suitable for testing the condition of the battery may be used.Additionally, load as used herein can also be a charge.

[0043] If the condition of the battery is such that the battery can berecharged, a preferred embodiment of the invention can calculate a settime to charge the battery. If LVB15 312 is less than 4.0 V, the settime, i.e., maximum charge time, equals approximately forty-fiveminutes. If LVB15 312 is equal to or greater than 4.0 V, the set chargetime is calculated as follows:

Set time=(12.5−Vss) * 56.25 minutes

[0044] Where,

[0045] Vss=bounce back voltage (“Rv”) if 11.7V<=Rv<=12.5V

[0046] Vss=12.5V if Rv>12.5 V

[0047] Vss=11.7V if Rv<11.7 V

[0048] By applying the heavy load test and monitoring the bounce backvoltage, the charger 100 calculates the state of charge of the batteryand the set time required to charge the battery while maintaining anoptimum charge rate. The charger 100 controls the optimum charge rate byprecisely controlling the charging voltage throughout the chargingcycle.

[0049] If the battery condition can be charged, as determined by theheavy load test (e.g., Sabre Battery Test), further testing and chargingwill be performed. If the battery condition is determined to be faulty,then testing is terminated and the battery can be discarded. Therefore,the operator does not waste time and effort to charge the defectivebattery.

[0050] If the battery condition is determined to be functional,additional testing and charging are performed, as depicted in FIG. 4.The first step in this testing is to determine whether the bounce backvoltage is greater than 12.6 volts 400. The bounce back voltage is ameasure of the state of battery charge. If the bounce back voltage isdetermined to be greater than 12.6 volts, the battery tester/chargerwill perform a micro-load test 162. If the bounce back voltage is equalto or less than 12.6 volts, the charger 100 is activated 402 to chargethe battery for a set time 404.

[0051] While the battery is being charged 402, the current is monitored.If the charge is greater than five amps 406, the charger 100 continuesto charge for the set time. If the current is less than or equal to fiveamps 406, the charger 100 continues to charge the battery for a minimumof at least five minutes 408.

[0052] Once the set time or five minutes of charging 408 is reached, thecharger 100 turns off 410. A heavy load test is applied to the batteryfor at least ten seconds followed by the heavy load 144 being removedfor at least twenty seconds 410. The previous application and removal ofthe heavy load 144 is important to condition the battery by stabilizingthe battery voltage. Another heavy load test 412 is then performed onthe battery.

[0053] The charger 100 then determines from the heavy load test 412 ifthe battery is good 414. If the battery is determined to be faulty orbad 416, the testing is terminated and the battery is discarded. If thebattery is determined to be functional 414, or if the bounce backvoltage is greater than 12.6 volts, the cold cranking amps (“CCA”) aremeasured using a micro-load test 418.

[0054] In the preferred embodiment, the micro-load test 418 is performedafter the battery is determined to be functional by the heavy load test412. This micro-load test 418 is performed by applying a smaller load(approximately twenty to sixty amps) for a preset duration(approximately 250 milliseconds to one second) and measuring the CCA 420after the micro-load 162 is removed. If the measured CCA is greater than70% of the rated CCA 420 of the battery, then the battery is good andthe charge is completed 424, then the cycle ends at 426. If the measuredCCA is less than 70% of the rated CCA 420 of the battery, then it is badbattery 422 and will be discarded. It should be recognized that othermicro-load tests could be substituted for the micro-load test 418described above. For example, a dual micro-load test can also be used.

[0055] If the condition of the battery can not be determined from theheavy load test 412, the charger 100 will charge the battery and retestit in accordance with the method depicted in FIG. 5. For re-testing, thecharger 100 is activated 500. The charger 100 charges the battery forapproximately one-minute 502. The battery voltage is read afterone-minute 504. If the battery voltage 504 is less than one volt afterone minute, the battery is bad. The charger 100 is then turned off andthe battery will be discarded 506.

[0056] If the voltage 504 is equal to or exceeds one volt after oneminute of charging, the charger 100 will continue to charge forapproximately nine minutes 508. During the nine minutes of charging, thecharging current is recorded or read at one-minute intervals todetermine if the charging current exceeds three amps 510. If thecharging current is equal to or does not exceed three amps, the batteryis determined to be bad 512 and the charger 100 is turned off and thebattery is discarded.

[0057] If the charger's 100 current does exceed three amps, the chargerwill continue to charge for the set period of time as calculated above514. The charger 100 will apply the heavy load 144 to the battery for aperiod of ten seconds to condition the battery and then removed theheavy load for a period of twenty seconds 516 for the battery voltage tostabilize. The heavy load test (e.g., Sabre Battery Test) is thenperformed 518.

[0058] The charger 100 then determines whether the battery is good 520.If the battery is determined to be bad 522, it is discarded. If thebattery is determined to be functional 520, the CCA is then measuredusing the micro-load test 524. The measured CCA is then compared to therated CCA for the battery 526. In the preferred embodiment of theinvention, if the measured CCA is less than or equal to approximatelyseventy percent of the rated CCA for the battery 526, then the batteryis determined to be bad 528 and is discarded. If the measured CCA 526 isgreater than approximately seventy percent of the CCA, then the batteryis determined to be good 530 and the charge is completed 532.

[0059] Referring to FIG. 1, the preferred embodiment contains aninfrared temperature sensor 164, which aids in monitoring both thecharger 100 and the battery being charged. The infrared temperaturesensor 164 ensures that both the battery and charger 100 are maintainedare safe levels. In the preferred embodiment, the infrared sensor 164 iscontained within a housing. The housing is placed over the chargingbattery for safety reasons especially in the instance that, whilecharging, the battery unexpectedly explodes. The housing aids incontaining the surrounding areas from the contaminants of the explodedbattery.

[0060] The infrared temperature sensor 164 is placed within the housingto monitor the temperature of a charging battery. While charging abattery, heat is discharged or dissipated from the battery. However,excessive heat is an indication that the battery is being charged at anexcessive rate. In the preferred embodiment, the infrared temperaturesensor 164 is linked to the ADC 136, essentially an input to the ADC136, which relays the information to the CPLD 140, which then relays itto the FPGA 142. The FPGA 142, with the help of the infrared temperaturesensor 164, can monitor the temperature of the battery and relay theinformation, including any problems to the operator. The infraredtemperature sensor 164 is aimed at the battery to ensure that thetemperature of the battery is being monitored throughout the chargingprocess. For example, if the battery being charged contains a short, thebattery will heat excessively in a short period of time. The feedbackfrom the infrared temperature sensor 164 can be used to alert theoperator of the problem so that the operator can take the appropriateaction.

[0061] A gel battery can heat excessively during charging and therefore,the charging current is applied in relation to the heat detected. Forthis type of battery, a temperature is fixed after which point thecharging current is reduced. By monitoring the temperature and adjustingthe current in view thereof, the charging time is reduced. Thetemperature and charging current are proportionally related in specifictypes of batteries (e.g. gel). Thus, by monitoring the temperature andthe charging current, the gel battery or other batteries can be chargedefficiently, and explosions can be prevented during charging.

[0062] In another embodiment, the infrared temperature sensor 164 can beaimed at the charger 100 only or in combination with the battery. Bymonitoring the charger 100, any excessive temperature generated by thecharger can be relayed to the operator, thus appropriate actions can betaken to avoid overheating and damaging the charger.

[0063] One of ordinary skill in the art recognizes that the temperaturesensor 164 can be located in a number of different locations, eitherlocated in the charger 100 or linked to the charger 100. The location ofthe infrared temperature sensor 164 is not limited to a housing.Additionally, temperature sensors are needed most when the battery ischarging. Therefore, monitoring the temperature of the battery and/orthe charger can help to prevent battery explosions.

[0064] In a preferred embodiment, a conventional processor is replacedby a dynamic FPGA 142. The use of the FPGA 142 allows a designer to makechanges to the charger 100 without having to replace the processor.Changes to a mounted conventional processor requires remounting andreconfiguration of the charger 100 design, which in turn requires moredesign hours. With the use of the FPGA 142, the designer is allowed tomake changes and additional costs on the fly without remounting ortireless reconfiguration of the initial design.

[0065] The FPGA 142 is configured and arranged to operate as aconventional processor. In the preferred embodiment the FPGA 142 controland processes a number of different functions of the charger 100. Onesuch function is the operation of the micro and heavy load tests 418,412. These tests are downloaded and stored into a memory device 144. Itcan also be stored in a RAM device 146. Once stored in these memorydevices 144, 146, the code is downloaded into the FPGA 142 and executed.Upon execution of the code, the FPGA 142 begins to operate variouscontrols of the charger 100, such as the solenoid switch 146 on theheavy load 144, and the SCR 126 for current and voltage control.Additionally, data can be inputted into the FPGA 142 through the inputdevice 148, such as a keypad. The FPGA 142 can transmit to and receiveinformation from an output display 150, a serial port 154, such as aprinter port, a second serial port 152, such as an infrared bar codereader, a module port 156 that can accept various communication modules,or any other device that can communicate with the FPGA.

[0066] Upon start-up or boot-up of the charger 100, an image of asoft-core microprocessor is loaded from the memory (i.e. flash 144, RAM146, etc.) into the FPGA 142. Therefore, there is an image of the FPGA142 resides in the memory. Additionally, upon start-up, the CPLD 140takes control of the data and address bus and clocks the FPGA 142 imagefrom memory into the FPGA 142. As stated previously, this allows forredesign of the processor and the board without the need for remountinga processor. All that is necessary for a design change is to upload anew FPGA image into the memory device. Additionally, any new tests oroperating parameters that is required by the operator can be easilyupload into the FPGA 142 and executed. The preferred embodiment usesflash memory 144 to accomplish this function.

[0067] The output display 150 can be an integrated display or a remotedisplay that relays information, such as data gathered from the chargingand testing of the battery, and menu information. Additionally, thedisplay 150 can notify the operator of any problems that have beendetected. The serial port 154 in the preferred embodiment are standardRS-232 serial ports for connecting a device such as a printer. One ofordinary skill in the art will recognize that the RS-232 can be replacedwith an RS-432, an infrared serial port or a wireless radio frequencyport, such as BLUETOOTH™, or any other similar device.

[0068] In some embodiments of the current invention, a bar code port 152is provided. The bar code port 152 may serve to operably connect a barcode reader (not shown) to the FPGA 142 or a microprocessor. In someembodiments, the bar code port 152 may be a conventional component, suchas an RS-232. The bar code reader may be, for example, a conventionaloptical bar code reader, such as a gun or a wand type reader.

[0069] The operator swipes or aims the bar code reader on a bar codethat is associated with the particular battery to be charged or testedand reads the bar code. The bar code itself may be affixed to thebattery at the time of manufacture, purchase, or service. The bar codemay contain information, or point to information stored in a database.The database may be located within the FPGA 142, the storage media 168(below) or located remotely and accessed electronically. Examples ofremotely located databases include data based accessible by theInternet, Ethernet, or other remote memory storage facility.

[0070] The bar code may provide a variety of information regarding thebattery. For example, the bar code may provide information regarding thebattery type (e.g. gel, flooded lead acid, deep cycle), the batteryrating (cold cranking amps), maintenance information, serial number, lotnumber, warranty information, and a manufacture date code. This data canbe used to select parameters for the test or charge cycle. The dataprovided by the bar code is not limited to the examples given.

[0071] In some embodiments, the printer port 154 may print bar codelabels that may be attached or otherwise associated with the battery andprovide updated information. The updated information may include, amongother things, service dates, service procedures, and warrantyinformation (e.g. time left on warranty, who was the original purchaser,what types of service are and are not warranted, etc.) The printed labelmay then be read by the bar code reader in subsequent tests or chargecycles.

[0072] The output display 150 and an input device 148 are illustrated ina preferred embodiment in FIG. 6. The display 150 and input device 148can be located preferably on a common face of a cabinet of the charger100, although they alternatively can be located remote from each otherand/or remote from the cabinet of the charger, if desired. The display150 can include one or more LED's indicating states of the charger 100or the battery during charging or testing. For example, LED 652indicates that power is applied to the unit, LED 653 indicates a chargeis being applied to the battery, LED 654 indicates a fault in thebattery, and LED 655 indicates a good battery is detected. A segmentedor dot matrix type, alphanumeric LCD display 656 may also be provided aspart of the output display 150. For example, as shown in FIG. 6, thedisplay 656 can be a 4 by 20 backlit LCD display, having four rows eachhaving twenty character columns. This permits display of a wide range ofinformation relating to e.g., charging status, time, amount, etc, aswell as display and selection from a menu of control functions. Thus,the display 150 can include either the alphanumeric display 656, theLED's 652 to 655 or both. The two types of displays can be on a singlepanel or separate ones.

[0073] Control functions may be inputted via at least one, preferablytwo and more preferably three or more functional buttons, such as updown buttons 658, and a menu select button 660. A ten key alphanumerickeypad 662 may also or alternatively be provided for input of numericdata, alphabetic data, and/or command selection. Each key can providefor entry of a number, one or more letters, and/or a function. Thus, theinput device 151 can include the menu button 660, the up down buttons658, the alphanumeric keypad 662, or a combination thereof. Thesearrangements can be on a single panel or separate ones.

[0074] For example, the key labeled GO may generally be used in theaffirmative. It usually means continue on. It is also used to initiatemenu prompts leading to the test/charge sequence. The key labeled CLEARcan generally be used in the negative. It is generally used to clear avalue that is to be entered. It may also be used to break out of aprocess or back out of a menu sequence. The key labeled MENU can be usedto initiate the function menu. It is also used to back out of a menusequence. The ARROW KEYS can be used to navigate within the menus anddisplay screens. If an arrow is displayed on the right of the display,the corresponding arrow key can be used to “move” the view to anotherpart of the menu or screen. The arrow keys may also be used to incrementor decrement a displayed value. The NUMBER KEYS can be used tocommunicate with the application in a number of ways. They can be usedto indicate the selection on a menu. They can also be used to providenumerical and/or alphabetical input to an application parameter.

[0075] The screen may include the ability to scroll through a set ofmenu items, such as for example, the following:

[0076] a) Top level menu, (GO or MENU)

[0077] b) Function Menu:

[0078] 1-Test Results

[0079] 1-View results

[0080] 1-Print results

[0081] 2-Print engineering data

[0082] 2-Print results

[0083] 2-Setup

[0084] 1-Set Clock

[0085] 2-Set Language

[0086] 3-Set Printer Port

[0087] 4-Ethernet Setup

[0088] 5-Save setup

[0089] 3-Self Test

[0090] 1-LCD Test

[0091] 2-keypad Test

[0092] 3-LED Test

[0093] 4-Audio Test

[0094] 5-Watchdog Test

[0095] 6-Load Cycle Test

[0096] 7-RAM test

[0097] 8-Checksum application

[0098] 9-Test Barcode Reader

[0099] 4-Update S/W

[0100] 5-Utility menu

[0101] 1-print codes

[0102] 2-upload data

[0103] 6-Calibrate

[0104] 1-Set DACO

[0105] 2-Set DAC1

[0106] 3-Set Amps Offset

[0107] 4-Set Amps Gain

[0108] 5-Set Volts Offset

[0109] 6-Set Volts Gain

[0110] 7-TemperatureOffset

[0111] 8-Manual Controls

[0112] 1-Test SCR

[0113] 2-Enable SCR load

[0114] 3-Enable Low Volts Charging

[0115] 4-Auto Charge Mode

[0116] 5-Heavy Load Test

[0117] 6-Micro Load test

[0118] 7-Manual Charge Mode

[0119] 8-Monitor Volts

[0120] 9-Save Calibrations

[0121] This menu is by way of example only. Other features, commands,displays or inputs, for example may also be provided.

[0122] Referring to FIG. 1 an additional smaller transformer 158provides current and voltage to the I/O control 134 and a cooling fan160. The smaller transformer 158 provides a step down of both thevoltage and current to a level that enables the I/O control 134 and acooling fan 160 to operate. The cooling fan 160 helps to control theoperating temperature of the charger 100.

[0123] The peripheral module port 156 can be constructed and arranged toreceive an information relay device, such as an Ethernet wired module166 and/or an Ethernet wireless module 164. The Ethernet modules 164,166 communicate at data rates of 10 Mbps (10Base-T Ethernet), 100 Mbps(Fast Ethernet), 1000 Mbps (Gigabit Ethernet), and other data rates. TheEthernet modules 164, 166 can relay information between the charger 100and another device connected to the modules via a wire or wirelessly.The information relayed can include data from the result of thecharging/testing of the battery, data of the battery's warrantyinformation, data of the battery type (deep cycle, gel, etc.), data ofbattery make and model, data from previous charging/testing of thebattery, firmware update, data from diagnostic or operating parametersof the charger 100, maintenance data of the charger 100, and any otherdata required by the operator.

[0124] The peripheral module port 156 is in communication with the FPGA142. Information can be exchanged between the peripheral module port156, the Ethernet modules 164, 166, and the FPGA 142. The Ethernetmodules 164, 166 can relay the information to and from a remote device,such as a network server, a printer, a personal computer, a workstation,a file server, a print server, other communication devices, such as afax machine, a cellular/digital phone, a pager, a personal digitalassistant, an email receiver, and a display. Through the use of theEthernet modules 164, 166 any information, such as the information ofthe battery tested by the charger 100 can be relayed to a printer serverand printed. Thus, the charger 100 is not dependent on a stand-aloneprinter that may be down, and can print to any networked printer,thereby saving time and money to the operator.

[0125] With the Ethernet module 164, 166, information can also be storedremotely, such as on a workstation, a file server or other data storagedevice. For example, after the charger 100 concludes thecharging/testing of the battery, the information from the test/chargecan be relayed and stored on a networked personal computer. With theinformation stored on the networked personal computer, the informationfrom any previous charge/test can be compared with the latestinformation, a report can be generated and forwarded to the appropriatepersonnel.

[0126] If the chargers 100 (same or similar model) that are used by theoperator are “networked” together, the chargers' firmware can be updatedsimultaneously. Conventionally, to update firmware, a laptop is hookedup to the charger 100 and the new firmware is uploaded. Once the uploadis completed, the operator then must go to the next charger 100 andrepeat the process until all of the chargers 100 are updated with thenew firmware. By being able to upload new firmware onto networkedchargers 100, the update process will be less time consuming, and thuscost-effective for the operator. By having the chargers 100 networkedvia the Ethernet modules 164, 166, information from all the chargers 100can be relayed and displayed to the operator. Because the chargers 100can be networked, the operator does not have check each individualcharger 100 to see if the charging and testing is completed and savevaluable time and money. Additionally, by being networked, the chargers100 can be instructed to run diagnostics and other functions remotelywithout having to individually program each charger 100.

[0127] In another embodiment, a notification system is provided tonotify the operator when there is a problem with the charger 100 or thebattery or when the charging/testing is completed. Typically, theoperator has to physically check the status of the charger 100 and oftenwould have to return many times to see if the charging/testing iscompleted. With the charger 100 having an Ethernet connection modules164, 166, the status information can be relayed to a remote location,such as the network server or the personal computer, which can beprogrammed to notify the operator of any problems or the completion ofthe charging/testing. Because the operator can be notified of anyproblems, the operator can take appropriate measures, such asterminating the charging of the battery because charger 100 or thebattery is overheating. By being notified of any problems, the operatorcan save money due to a decrease in electricity usage and decrease thepossibility of an explosion due to overcharging the battery.Notification of the operator can be done with a personal computer thatcan notify the operator via another display, by pager, by fax, by email,by phone, by computer or by any means that will relay the requestedinformation to the operator.

[0128] In another embodiment of the invention, the peripheral moduleport 156 can be constructed and arranged to accept a removable datastorage media 168 (“storage media”). Information can be exchangedbetween the peripheral module port 156, the storage media 168, and theFPGA 142. The storage media 168 can be permanently fixed to the charger100 to provide additional memory or can be removable, as required by theoperator. The storage media 168 can transfer information to and from thecharger 100. The information can include data from the result of thecharging/testing of the battery, the battery's warranty information, thebattery type (deep cycle, gel, etc.), battery make and model, data fromprevious charging/testing of the battery, firmware update, data fromdiagnostic or operating parameters of the charger 100, maintenance dataof the charger 100, and any other data required by the operator.

[0129] The storage media 168 can include, but not limited to floppy disc(including ZIP); tape drive cartridge (such as DAT); optical media (suchas CD-ROM, DVD-ROM, etc.); flash memory (such as smart media, compactflash, PC card memory, memory sticks, flash SIMMs and DIMMS, etc.);magnetic based media, magneto optical; USB drives; or any other storagemedia that an operator can store or retrieve information from it. Aperson skilled in the art will recognize that any storage media can beused.

[0130] One use of the storage media 168 is to update firmware, whereinthe storage media can be programmed with the firmware update and loadedinto the charger 100. By using the user interface 148, the operator canselect the “update firmware” option from a menu that was previouslyprovided to the charger 100. The charger 100 is able to retrieve the newfirmware and update the charger 100. In another example, the operatorcan use the storage media 168 to store information regarding the batterythat was charged/tested. The information can be downloaded into thestorage media 168, such as a compact flash card, and can be sent to theappropriate person. Additionally, the storage media 168 can containinformation from the charging/testing result of a battery at anotherlocation and can be uploaded into the charger 100 and displayed to theoperator. Alternatively, the information can be relayed via the Ethernetmodule to be viewed, stored, or printed at a remote location. Thestorage media 168 can also provide an image of a soft-coremicroprocessor to the FPGA 142 during start-up. By having the storagemedia 168, the files relating to information, the results from previoustests charges, can be easily matched up to the battery and electronicfiles are stored in less space than their equivalent amount in paperfiles.

[0131] The charger 100 can have more than one peripheral module port 156so that a communication nodule, a storage media module, and an manyother modules as needed can be onboard the charger. The peripheralmodule port 156 provides flexibility to the charger 100 and provides aport so that any new device can be added to the charger as needed by theoperator.

[0132] The many features and advantages of the invention are apparentfrom the detailed specification, and thus, it is intended by theappended claims to cover all such features and advantages of theinvention which fall within the true spirits and scope of the invention.Further, since numerous modifications and variations will readily occurto those skilled in the art, it is not desired to limit the invention tothe exact construction and operation illustrated and described, andaccordingly, all suitable modifications and equivalents may be resortedto, falling within the scope of the invention.

What is claimed is:
 1. A charging apparatus, comprising: a power sourcecharger having a module port; and a removable data module received inthe module port and is in communication with the power source charger.2. The charging apparatus of claim 1, wherein the power source chargeris also a tester.
 3. The charging apparatus of claim 1, wherein thepower source charger further comprises a controller that is incommunication with the removable data module.
 4. The charging apparatusof claim 3, wherein the controller can store data on the removable datamodule.
 5. The charging apparatus of claim 3, wherein the controller canretrieve data contained in the removable data module.
 6. The chargingapparatus of claim 1, wherein the removable data module can be selectedfrom a group consisting of a floppy disc, a tape drive cartridge, anoptical media, a flash memory, a magnetic based media, a magnetooptical, a hard drive, any other removable media and a combinationthereof.
 7. The charging apparatus of claim 1 wherein the removable datamodule's data can be selected from a group consisting of the result ofthe charging/testing of the battery, the battery's warranty information,the battery type, the battery brand, the battery model, previousinformation regarding charging/testing of the battery, firmware update,diagnostic or operating parameters information of the charger,maintenance information of the charger, any other data required by theoperator, and a combination thereof.
 8. A method of storing andretrieving data for a charging apparatus, comprising: operating thecharging apparatus; and accessing a removable data module by amicroprocessor.
 9. The method of claim 8, wherein the charging apparatusfurther comprises a tester.
 10. The method of claim 8, wherein operatingthe charging apparatus is charging the battery.
 11. The method of claim9, wherein operating the charging apparatus is testing the battery. 12.The method of claim 8, wherein accessing the removable data module isstoring data resulting from operating the battery charger.
 13. Themethod of claim 8, wherein accessing the removable data module isretrieving previously stored data.
 14. The method of claim 8, whereinthe removable data module can be selected from a group consisting of afloppy disc, a tape drive cartridge, an optical media, a flash memory, amagnetic based media, a magneto optical, a hard drive, any otherremovable media, and a combination thereof.
 15. A charging system,comprising: a power source charger means having a module receivingmeans; and a removable data means is received in the module receivingmeans and is in communication with the power source charger means. 16.The charging system of claim 15, wherein the power source charger meansfurther includes a power source testing means.
 17. The charging systemof claim 15, wherein the power source charger means further comprises acontroller means that is in communication with the removable data means.18. The charging system of claim 17, wherein the controller means cancontrol and store data onto the removable data means.
 19. The chargingsystem of claim 17, wherein the controller means can control andretrieve data from the removable data means.
 20. The charging system ofclaim 15, wherein the removable data means can be selected from a groupconsisting of a floppy disc, a tape drive cartridge, an optical media, aflash memory, a magnetic based media, a magneto optical, a hard drive,any other removable media, and a combination thereof.